ted225 course packet fa01 - preparation, conditioning, forming, shaping, and finishing of these...

TED 226 Application and Processing of Engineering Materials

Course Packet

Revised Spring 2006

Dr. Larry Horath

Applied Engineering & Technology

California University of Pennsylvania

Office: Eberly 160C

Phone: 938-4085

Horath@cup.edu

Table of Contents

Calendar………………….…………………………………………3

Syllabus…………….……………………………………………….4

Weblinks…………………………………………………………….9

Information Sheet on the Structure of Materials………….………..13

Information Sheet on the Making of Steel……………………….....19

Information Sheet on the Structure of Steel………………………...28

Common Shapes…………………………………………………….29

Information Sheet on Nonferrous Metals…………………………...30

Information Sheet on Technical Ceramics and Related Materials….32

Information Sheet on Polymeric Materials………………………….38

Summary Sheet on Polymers and Plastics…………………………..47

Plastic Processing Sheets……………………………………………51

Fuels and Lubricants………………………………………………...73

Information on the Testing and Evaluation of Materials……………74

Laboratory Reports, Homework, Research, and Projects…………...92

Utility Tray…………………………………………………………..94

Chisel………………………………………………………………...95

Boot Scraper…………………………………………………………96

ScrewDriver………………………………………………………….97

Research Questions………………………………………………….98

Homework Assignment……………………………………………...99

Study Guide Questions……………………………………………..101

TED 226 - Calendar

Week 1 Introduction Policies Safety Glasses Required Tour of Facilities Structure of Materials

Week 2 Structure of Materials (cont.) Primary Processing Projects Overview Safety Quizzes Handouts

Week 3 Intro Metallic Materials Secondary Processes Utility Tray Properties of Materials

Week 4 Fabricating Materials Forming Sheet Metal Casting & Molding

Week 5 Casting & Molding (cont.) Shear, Brake, Bar Folder Fabrication Elements Forging Heat Treatment Chisel

Week 6 Heat Treating (cont.) Joining Metals Fasteners Welding, Brazing, Soldering

Week 7 Review Test #1 Boot Scraper Adhesives & Coatings

Week 8 Review Test Intro Plastics Plastics Processing: Injection Molding; Vaccum, Compression, Dip, Rotational, etc. Screwdriver

Week 9 Fabricating Plastic Products Processing Methods Hot Melt Adhesives Conditioning/Finishing Handouts

Week 10 Review Handouts Ceramics/Glass Exam #2

Week 11 Intro Material Testing Review Properties

Week 12 Tensile Properties & Testing Compressive Properties & Testing Shear Properties & Testing

Week 13 Flexure Properties & Testing Hardness Testing & Properties Impact Testing & Properties Non-destructive Evaluation Review for Test#3

Week 14 Original Test Apparatus Design Review Test#3 Lab Cleanup/Review

Week 15 All Projects Due End of Class Return Projects Final Review/Grade

Syllabus

1. Course Number: TED 226 Course Name: Application and Processing of Engineering Materials

Credits: 3 Prerequisite: None 2. Instructor: Dr. Larry Horath or any qualified TED faculty member 3. Rationale for the Course:

Students are required to develop technological literacy, especially those aspiring to become technology education teachers. This course addresses the needed skills and competencies and serves as an introduction to metallic, ceramic, and plastic materials including the selection, preparation, conditioning, forming, shaping, and finishing of these materials. There will be approximately two lecture hours and four laboratory hours per week which allow students to explore facets of materials science, selection, processing, and testing. This course will further serve as the skills foundation for other laboratory courses that require the processing of materials.

4. Objectives:

Upon successful completion of this course the student will be able to

a. Describe primary and secondary methods of processing common industrial materials.

b. Identify and differentiate between different industrial materials.

c. Define, describe and evaluate different physical, mechanical, chemical, thermal, electrical, and other common properties.

d. Analyze various properties through accepted, standardized tests.

e. Use permanent and consumable molds to produce castings. f. Identify the various molding and casting techniques along with their advantages, disadvantages, and applications. g. Change the shape of metallic, ceramic, and plastic materials

using a variety of techniques including cold and hot forming, extruding, blow molding, calendering, and mechanical forming.

h. Perform common lathe and milling operations to shape materials. i. Identify and properly apply various mechanical fasteners. j. Apply electric arc welding, oxy-acetylene welding, brazing, and

soldering processes in joining similar and dissimilar materials. k. Perform drilling, sawing, tapping, grinding, sanding, and

similar common industrial processes. l. Cut, trim, and shape metallic materials using a variety of techniques such as flame cutting,

shearing, and assorted hand tools. m. Heat treat metals using annealing, normalizing, hardening, tempering, and work hardening. n. Chemically condition plastic materials using catalytic action and polymerization.

o. Assemble various materials using mechanical fasteners, adhesives, and cohesive processes. p. Apply suitable surface finish preparation techniques, correctly select a proper finish, and properly

apply the finish for a variety of materials.

5. Proposed Catalog Description:

This course is designed to serve as an introduction to metallic, ceramic, and plastic materials including the selection, preparation, conditioning, forming, shaping, and finishing of these materials. There will be approximately two lecture hours and four laboratory hours per week. These activities allow students to explore the many facets of materials science, selection, processing, and testing. Additionally, this course serves as the foundation for other laboratory courses that require the processing of materials.

6. Detailed Outline A. Introduction and Orientation 1. Syllabus 2. Topic Schedule and Calendar 3. Policies and Procedures 4. Safety Issues B. Properties of Materials 1. Materials Science and Selection 2. Chemical Basis for Materials and Properties 3. Physical Properties 4. Chemical Properties 5. Mechanical Properties 6. Thermal Properties 7. Electrical Properties 8. Other Factors C. Types of Processing 1. The Nature of Manufacturing a. Primary Processing b. Secondary Processing c. Casting and Molding d. Separating and Shaping e. Conditioning f. Assembling and Joining g. Finishing 2. Types of Industrial Materials a. Metals b. Wood c. Polymers d. Ceramics e. Composites f. Other 3. Summary D. Casting and Molding 1. Introduction to Casting and Molding Processes a. Historical Background and Development b. Common Industrial Types c. Advantages and Disadvantages d. Details and Applications 2. Casting Metals Using Consumable Molds

a. Sand Casting b. Shell Mold Casting c. Investment Casting d. Other 3. Casting Metals Using Permanent Molds a. Slush Casting b. Die Casting c. Centrifugal Casting d. Other 4. Casting and Molding Plastic Materials a. Gravity Casting b. Injection Molding c. Compression Molding d. Blow Molding e. Transfer Molding f. Rotational Molding g. Dip Casting h. Slush Casting I. Foaming 5. Summary E. Forming and Shaping 1. Introduction to Forming and Shaping a. Basic Techniques in Forming b. Common Devices Used to Form and Shape Materials c. Temperature as a Factor in Forming and Shaping d. Methods of Applying Force in Forming and Shaping 2. Hot Forming Materials a. Advantages and Disadvantages b. Techniques c. Safety Concerns 3. Cold Forming Materials a. Advantages and Disadvantages b. Techniques c. Safety Concerns 4. Forming and Shaping Plastics a. Thermoforming b. Extrusion c. Blow Molding d. Calendering e. Mechanical Forming 5. Summary F. Separating Materials 1. Introduction to Separating Techniques a. Process Development b. Elements and Techniques c. Machines and Motion d. Proper Selection, Support, and Safety 2. Turning and Related Operations a. Turning b. Facing

c.